Method for additively manufacturing at least one three-dimensional object

Abstract

Method for additively manufacturing at least one three-dimensional object ( 2 ) by means of successive layerwise selective irradiation and consolidation of build material layers ( 3 ) by means of at least one energy beam ( 5 ), comprising irradiating and thereby consolidating an irradiation area (A) which is to be selectively irradiated and thereby consolidated of a first build material layer ( 3 ); and irradiating the irradiation area (A) of the second build material layer ( 3 ) in an area above the at least one sub-area (SA) of the irradiation area (A) of the first build material layer ( 3 ) in such a manner that the at least one sub-area (SA) of the irradiation area (A) of the first build material layer ( 3 ) is consolidated.

1 . Method for additively manufacturing at least one three-dimensional object ( 2 ) by means of successive layerwise selective irradiation and consolidation of build material layers ( 3 ) by means of at least one energy beam ( 5 ), characterized by
 irradiating and thereby consolidating an irradiation area (A) which is to be selectively irradiated and thereby consolidated of a first build material layer ( 3 ), whereby at least one sub-area (SA) of the irradiation area (A) which is at least partly disposed below at least one irradiation area (A) which is to be selectively irradiated and thereby consolidated of a second build material layer ( 3 ) which is disposed directly above the first build material layer ( 3 ) is excluded from being irradiated and thereby consolidated; and   irradiating the irradiation area (A) of the second build material layer ( 3 ) in an area above the at least one sub-area (SA) of the irradiation area (A) of the first build material layer ( 3 ) in such a manner that the at least one sub-area (SA) of the irradiation area (A) of the first build material layer ( 3 ) is consolidated.   
     
     
         2 . Method according to  claim 1 , wherein the or at least one area of the irradiation area (A) of the second build material layer ( 3 ) which is disposed above a respective sub-area (SA), particularly the or at least one selected sub-area (SA), of the first build material layer ( 3 ) is irradiated with a different irradiation parameter set compared with a reference irradiation parameter set applied for irradiation the remaining portions of the second build material layer ( 3 ), particularly with a different irradiation parameter set resulting in a higher energy input into this area of the irradiation area (A) of the second build material layer ( 3 ) compared with the reference irradiation parameter set. 
     
     
         3 . Method according to  claim 1 , wherein by irradiating the irradiation area (A) of the at least one second build material layer ( 3 ), a vertically extending consolidating region is built which at least comprises portions of the irradiation area (A) of the at least one second build material layer ( 3 ) which are to be selectively irradiated and thereby consolidated as well as the at least one sub-area (SA) of the first build material layer ( 3 ). 
     
     
         4 . Method according to  claim 1 , wherein by irradiating the irradiation area (A) of the at least one second build material layer ( 3 ), a vertically extending structural element ( 13 ) is generated which at least comprises selectively irradiated and thereby consolidated portions of the irradiation area (A) of the at least one second build material layer ( 3 ) and the at least one sub-area (SA) of the first build material layer ( 3 ). 
     
     
         5 . Method according to  claim 4 , wherein a vertically extending structural element ( 13 ) is generated with a two-dimensional or three-dimensional shape and/or a two-dimensional or three-dimensional extension through the three-dimensional object ( 2 ) which is to be additively manufactured. 
     
     
         6 . Method according to  claim 4 , wherein for generating a vertically extending structural element ( 13 ) a different irradiation parameter set compared with a reference irradiation parameter set applied for irradiating the remaining portions of the respective irradiation area (A) of the respective build material layer ( 3 ), particularly a different irradiation parameter set resulting in a higher energy input into the build material layers ( 3 ) compared with the reference irradiation parameter set, is used. 
     
     
         7 . Method according to  claim 4 , wherein a plurality of vertically extending structural elements ( 13 ) are generated which are uniformly or non-uniformly distributed throughout the three-dimensional object ( 2 ) which is to be additively manufactured. 
     
     
         8 . Method according to  claim 4 , wherein vertically and/or horizontally offset, in particular vertically and/or horizontally stacked, vertically extending structural elements ( 13 ) are generated. 
     
     
         9 . Method according to  claim 4 , wherein vertically extending structural elements ( 13 ) are built which are adjacently disposed so as to generate a staircase-like arrangement ( 14 ). 
     
     
         10 . Method according to  claim 9 , wherein a plurality of staircase-like arrangement ( 14 ) are generated which are uniformly or non-uniformly distributed throughout the three-dimensional object ( 2 ). 
     
     
         11 . Method according to  claim 4 , wherein a respective vertically extending structural element ( 13 ) having a vertical extension of the sum of the layer thicknesses of the respective build material layers ( 3 ) through which the vertically extending structural element ( 13 ) extends in vertical direction is generated. 
     
     
         12 . Method according to  claim 4 , wherein respective vertically extending structural elements ( 13 ) and/or staircase-like arrangements ( 14 ) are disposed in such a manner so as to concertedly adjust the structural properties, particularly the mechanical properties, of the three-dimensional object ( 2 ) which is to be additively manufactured. 
     
     
         13 . Control unit ( 6 ) for an apparatus ( 1 ) for additively manufacturing at least one three-dimensional object ( 2 ) by means of successive layerwise selective irradiation and consolidation of build material layers ( 3 ) by means of at least one energy beam ( 5 ), the control unit ( 6 ) being configured to, particularly in accordance with a method according to  claim 1 ,
 control irradiating and thereby consolidating an irradiation area (A) which is to be selectively irradiated and thereby consolidated of a first build material layer ( 3 ), whereby at least one sub-area (SA) of the irradiation area (A) which is at least partly disposed below at least one irradiation area (A) which is to be selectively irradiated and thereby consolidated of a second build material layer ( 3 ) which is disposed directly above the first build material layer ( 3 ) is excluded from being irradiated and thereby consolidated; and   control irradiating the irradiation area (A) of the second build material layer ( 3 ) in an area above the at least one sub-area (SA) of the irradiation area (A) of the first build material layer ( 3 ) in such a manner that the at least one sub-area (SA) of the irradiation area (A) of the first build material layer ( 3 ) is consolidated.   
     
     
         14 . Apparatus ( 1 ) for additively manufacturing at least one three-dimensional object ( 2 ) by means of successive layerwise selective irradiation and consolidation of layers of build material ( 3 ) by means of at least one energy beam ( 5 ), comprising a control unit ( 6 ) according to  claim 13 .